Digital printing has no printing plates, so it suits short and medium runs, many versions, variable data and frequent artwork changes. Flexographic printing uses plates and suits long runs of the same design and some special inks, with a higher set-up but a lower cost per label at volume. Finishes such as foil, varnish, embossing and die-cutting can be combined with both. The right choice depends on quantity per version, not on the total.
- Decide on quantity per version, not total quantity.
- Many versions, languages, vintages or variable data point to digital.
- Long, stable runs of one design point to flexo.
- Check which brand colours each process reaches on your material.
- Many ranges use both: digital for short SKUs and launches, flexo for long runners.
Decision table
| Criterion | Digital | Flexo |
|---|---|---|
| Printing plates | None | One per colour |
| Set-up cost | Low | Higher (plates, make-ready) |
| Best run length | Short and medium, per version | Long runs of the same design |
| Versions and languages | Easy, in the same job | Each version adds plates and set-up |
| Variable data | Native: numbers, codes, QR per label | Limited without extra equipment |
| Artwork changes | Fast and inexpensive | New plates for changed colours |
| Brand spot colours | Built from process inks; check gamut | Dedicated spot inks |
| Finishes | Foil, varnish, embossing, die-cut | Foil, varnish, embossing, die-cut |
Why quantity per version decides
An order of 50,000 labels across 25 flavours is, for the press, 25 jobs of 2,000. In flexo each version needs its own plates and set-up; in digital, versions follow each other without plates. Count versions before comparing offers. See the quote specification checklist.
Colour
Flexo usually prints brand colours with dedicated spot inks. Digital builds colours from a set of process inks; modern workflows with extended gamut reach many spot colours, but not every one on every material. Check critical colours on a printed sample. See how to keep label colour consistent.
Using both
Many groups split their range: long runners in flexo, launches, limited editions, seasonal and low-volume SKUs in digital. Common materials, colour targets and master samples keep both looking the same on the shelf.
Not sure which fits?
Send quantities and number of versions through the quote request form, or get an indicative price from a photo of your label.
Frequently asked questions
Is digital label printing cheaper than flexo?
For short runs and many versions, usually yes, because there are no plates. For long runs of one design, flexo is usually cheaper per label.
Can digital labels have foil and embossing?
Yes. Finishes such as hot foil, screen varnish, embossing and die-cutting are applied after printing in both processes.
Does digital printing match brand colours?
Many, but not all spot colours are reachable on every material. Check critical colours on a printed sample.
Which process is better for variable data?
Digital: numbers, codes and QR codes can change on every label.